TOPIC:

Here are a couple articles from bikeexif

www.bikeexif.com/kawasaki-zephyr

www.bikeexif.com/kawasaki-z1

www.bikeexif.com/z2-kawasaki

nelson,
pictures tell a thousand words.you have been working on these bikes long enough to look at some good pictures and pic out 95 percent of what has been done.
japanese does not translate very well(although googles language tools try to).
here is sanctuary's blog index.there are seven,i have been through four of them.so now i am off to see some more .

www.ac-sanctuary.co.jp/blogs/index.html

leon

Wow, it's been 9 weeks since I have updated this thread. As promised, I have been riding, and doing all the usual summer stuff with the kids. Juggling numerous other side projects. Well since I have about 10 balls in the air, the KZ ball was bound to come back down eventually. If you remember that thread that I started about the chopper frame here: kzrider.com/forum/11-projects/461220-chop-till-you-drop The main reason that I bought that project was for the mostly complete 1015cc KZ motor that was included.

So I decided to try and re-organize the garage today, so I can start tearing into the CB750f. The KZ motor is currently an obstacle to that effort so, I started to tear into the thing this evening. Wow that thing is dirty. So the PO already had the head off, and I got the jugs pulled easily. Pistons are off, and the good news is that the jugs are in good shape. No busted fins, and the bores are good candidates for a 72mm bore. Pistons don't look too bad either, but are worn. The bad news is that I don't have great hope for the head. It does have broken fins on one corner, and all of the timing chain tensioners are torched. I wonder what sort of shape the valves are in? That's no matter anyway, this will make a perfect practice head when I finally get my DIY flow bench built.

Hopefully I can get the rest of the motor dismantled tomorrow so I can organize and store parts. All I really need is the jugs, so I can clean them up and they will be off to be bored once I get the new pistons. We'll see how tough that alternator rotor is on this motor. Does anybody want to see pictures of nasty engine bits? I guess the tensioners will be interesting to look at. Looks to me like someone kept going after the ugly noises started in there. This one looks like it broke off in there and got spun around by the chain for a while:



I'll try and get some pictures tomorrow for the interested parties.

Got the rest of the spare motor dis-assembled tonight. Once again the old top clamp bolt and 1/2" drive impact gun did the trick. I must just have the most alternator ass kickin, clutch hub nut bustin, counter sprocket nut bustin, cheap ass impact gun ever. I got all three busted loose by holding the part with my left hand and the impact gun did the rest. Just cranked up the air regulator to 120 psi and let her rip. I still feel like everyone has a hard time with the alternator due to the use of long bolts. That top clamp bolt is short and wont twist to absorb the impact like a long bolt will.

Typical 30 year old KZ motor, it's cleaner inside than out. Trans, clutch, and crankshaft "look" good. I haven't measured anything, and won't for a while, but based on appearances, it's good. However, like I said yesterday, the cam chain rollers are roached. Have a look:






Compare that one follower to the picture of the new one from last night. It broke off at the screw on top and the bottom broke as well. Looks like that chain was bearing down on that guy for a while. Guess that's why Larry always advises everyone to replace this stuff when you are in there. I know it adds up, but I bet this one was lucky that the chain didn't skip and crash the valves. I can't find any marks on the pistons, but I haven't even looked at the head yet.

good catch man.if that went much longer i bet things would have gotten real ugly.although these are some tuff engines.

leon

I decided to start cleaning up the cases for the spare motor. Started by soaking those dirty things with a little ATF. This seems to break up the grease fairly well. Then I found a good shade tree to set up under and let fly with the pressure washer. Not shiny and beautiful yet, but at least they aren't nasty and greasy. Nothing cuts grunge like 2600psi.

Before:





After:

Man ur gonna have your hands full with all of these new project bikes.
Have fun with them bud.
what did u use for the shifter linkage ? the part that atatches to the shifter shaft. 83 GPZ ?

mark1122 wrote: Man ur gonna have your hands full with all of these new project bikes.
Have fun with them bud.
what did u use for the shifter linkage ? the part that atatches to the shifter shaft. 83 GPZ ?

You got that right. Did I mention I bought a boat also?

I made the shift linkage. Initially, I tried using the linkage from the 95 GSXR, but the splines are different. I ground it out a little, but then I couldn't get it tight. I tried searching for a link on ebay, but when I realized that getting the spline right would be a crapshoot, I decided to make it myself rather than pay $30 a piece for links that may or may not work. Here's a couple of new shots so you can see for yourself.

i like em better for sure...very very clean...the bike is clean too...very nice...a lot of work...nice

Wow, does that bike look nice! I too like the new rearsets, but I may need to build mt street cred back up after being MIA for so long....

crap. I'm still trying to figure out why I don't own a pressure washer... sure woulda been handy but too late now.